Solutions

Die Casting

Simply Profitable: Simulation in High Pressure Die Casting

The path to lower costs begins with the systematic reduction and elimination of costly casting trials and tooling modifications prior to production. Less scrap, reduced rework and fewer customer rejects all improve your bottom line. Reduced costs give you the edge over your competition.

Desirable die casting processes are characterized by casting conditions that avoid gas inclusions, porosity and cold laps but at the same time provide optimal filling characteristics and short cycle times. Economic production aims at an optimum die temperature control, a long die life, small cycle material amounts and perfectly set machine parameters. Using casting process simulation, die casters gain a deeper understanding of their processes and can adjust die design, casting parameters and runner design in such ways that castings of optimal quality can be produced in economical and robust manufacturing processes.

Simulation of turbulence formation and resulting gas inclusions with the MAGMAhpdc module

Understanding and optimizing processes through simulation comprises:

Realistic and detailed mapping of all process steps

Optimization of the filling process and the cooling of the melt in the shot sleeve

Reduction of die costs by evaluating the die design regarding heat-checking and lifetime

Reduction of cycle times through optimization of heating and cooling channels

Reduction of quality costs by avoiding casting defects that arrive from cold laps, turbulence, air entrapment, gas porosity, and shrinkage

Time savings and a robust layout of ingates, runners and vents, vacuum channels and overflows

Early and reliable decisions through quantitative predictions of component or tool properties

Reduction of production risks by using a high pressure die casting calculator for the rigging layout